ABB ACx580-01-02A6-4, Service Instructions Manual

Page 1: ... ABB Oy Drives Service ACx580 01 R0 R5 Related to material Department Date Revision Page ESP300 13 08 2018 F 1 41 Copyright 2018 ABB Oy All rights reserved Specifications subject to change without notice On site Service Instructions for ACx580 01 Frames R0 R5 ...

Page 2: ...g fan 18 2 2 11 New Frame R3 Main cooling fan 19 2 2 12 Old Frame R3 Main cooling fan 22 2 2 13 New Frame R3 IP55 Internal cooling fan Error Bookmark not defined 2 2 14 Old Frame R3 IP55 Internal cooling fan 23 2 2 15 Frame R4 Main cooling fan 24 2 2 16 Frame R4 IP55 Internal cooling fan 25 2 2 17 Frame R5 Main cooling fan 26 2 2 18 Frame R5 Internal cooling fan 27 2 2 19 Old Frame R5 Main cooling...

Page 3: ...d 3 There is no voltage between terminals R and R and the ground Also make sure that no one can accidentally power the system up while you re working on the drive All insulation tests must be carried out with the ACX580 disconnected from the cabling Do not make any insulation or voltage withstand tests on any part of the drive The ACX580 motor cable terminals are at a dangerously high voltage when...

Page 4: ... 1 2 Content The purpose of this document is to specify on site maintenance and repair actions of ACx580 01 frame sizes R0 R5 Following actions are included in this document Control unit replacement Cooling fan replacement 1 3 Required tools ESD field service kit Cross head screwdriver Flathead screwdriver Torxhead screwdriver 1 4 Maintenance schedule Maintenance schedule is available at ABB libra...

Page 5: ...t clean Too high operating temperature causes faster aging of the drive components In a normal environment the heat sink should be checked annually and cleaned if needed in a dusty environment more often Heat sink must also be cleaned when replacing a cooling fan NOTE Compressed air or normal vacuum cleaner must NOT be used to clean any other parts of the drive than heat sink only Airflow causes a...

Page 6: ...03A3 4 ACx580 01 04A0 4 ACx580 01 05A6 4 The main cooling fan is located at the bottom of the drive Replace the fan as follows a Release the locking clamp use a flathead screwdriver to assist b Remove the fan by opening the unit 1 and pushing leftwards at the base 2 c Clean the cooling air duct and the heat sink with compressed air See separate instructions in section 2 1 1 d Check that the fans b...

Page 7: ...A6 4 ACx580 01 03A3 4 ACx580 01 04A0 4 ACx580 01 05A6 4 Remove front cover a Remove control panel b Open mounting screw with a screwdriver c Push the front cover slightly upwards and lift it off Replace internal fan a Remove internal fan sledge from plastic housing b Assembly new internal fan sledge combination i Place internal fan to sledge ensure correct blowing direction ii Place FR 1 rivets th...

Page 8: ...in cooling fan Types ACX580 01 04A6 2 ACX580 01 04A7 2 ACX580 01 06A6 2 ACX580 01 06A7 2 ACX580 01 07A5 2 ACX580 01 07A6 2 ACX580 01 10A6 2 ACX580 01 012A 2 ACX580 01 017A 2 ACX580 01 018A 2 ACX580 01 02A1 4 ACX580 01 02A7 4 ACX580 01 03A0 4 ACX580 01 03A4 4 ACX580 01 03A5 4 ACX580 01 04A1 4 ACX580 01 04A8 4 ACX580 01 05A7 4 ACX580 01 06A0 4 ACX580 01 07A3 4 ACX580 01 07A6 4 ACX580 01 09A9 4 ACX58...

Page 9: ...ations subject to change without notice Replace the fan as follows 1 Release two locking clamps use a flathead screwdriver to assist 2 Remove the fan 3 Clean the cooling air duct and the heat sink with compressed air See separate instructions in section 2 1 1 4 Check that the fan blowing direction is outside the unit and install the new fan in reverse order to above Ensure the fan operation when t...

Page 10: ...0 01 07A5 2 ACX580 01 07A6 2 ACX580 01 10A6 2 ACX580 01 012A 2 ACX580 01 017A 2 ACX580 01 018A 2 ACX580 01 02A1 4 ACX580 01 02A7 4 ACX580 01 03A0 4 ACX580 01 03A4 4 ACX580 01 03A5 4 ACX580 01 04A1 4 ACX580 01 04A8 4 ACX580 01 05A7 4 ACX580 01 06A0 4 ACX580 01 07A3 4 ACX580 01 07A6 4 ACX580 01 09A9 4 ACX580 01 012A 4 ACX580 01 12A7 4 Remove the front cover You will find the internal cooling fan on ...

Page 11: ...ransparent plastic cover and the wires 2 2 5 Old Frame R1 Main cooling fan Types ACX580 01 07A2 4 ACX580 01 09A4 4 ACX580 01 12A6 4 The main cooling fan is located at the bottom of the drive Replace the fan as follows a Release two locking clamps use a flathead screwdriver to assist b Remove the fan c Clean the cooling air duct and the heat sink with compressed air See separate instructions in sec...

Page 12: ...CX580 01 07A2 4 ACX580 01 09A4 4 ACX580 01 12A6 4 Remove front cover a Remove control panel b Open mounting screw with a screwdriver c Push the front cover slightly upwards and lift it off Replace internal fan a Remove internal fan sledge from plastic housing b Assembly new internal fan sledge combination i Place internal fan to sledge ensure correct blowing direction ii Place FR 1 rivets through ...

Page 13: ...All rights reserved Specifications subject to change without notice 2 2 7 New Frame R2 Main cooling fan Types ACX580 01 024A 2 ACX580 01 025A 2 ACX580 01 031A 2 ACX580 01 032A 2 ACX580 01 014A 4 ACX580 01 018A 4 ACX580 01 023A 4 ACX580 01 03A9 6 ACX580 01 06A1 6 ACX580 01 09A0 6 ACX580 01 011A 6 ACX580 01 017A 6 The main cooling fan is located on the top of the drive Replace the fan as follows ...

Page 14: ...ed Specifications subject to change without notice 1 Release the two locking clamps use a flathead screwdriver to assist 2 Remove the fan 3 Clean the cooling air duct and the heat sink with compressed air See separated instructions in section 2 1 1 4 Check that the fans blowing direction is outside the unit and install the new fan in reverse order to above Ensure the fan operation when the drive i...

Page 15: ...g fan Types ACX580 01 024A 2 ACX580 01 025A 2 ACX580 01 031A 2 ACX580 01 032A 2 ACX580 01 014A 4 ACX580 01 018A 4 ACX580 01 023A 4 ACX580 01 026A 4 ACX580 01 02A7 6 ACX580 01 03A9 6 ACX580 01 06A1 6 ACX580 01 09A0 6 ACX580 01 011A 6 ACX580 01 017A 6 Remove the front cover You will find the internal cooling fan on the right side of the drive 1 Remove the transparent plastic cover in front of the fa...

Page 16: ...o material Department Date Revision Page ESP300 13 08 2018 F 16 41 Copyright 2018 ABB Oy All rights reserved Specifications subject to change without notice 3 Assembly the new internal fan and check that the blowing direction is to downwards Remember to reinstall the transparent plastic cover and the wires ...

Page 17: ...ling fan Types ACX580 01 017A 4 ACX580 01 025A 4 The main cooling fan is located at the bottom of the drive Replace the fan as follows a Release two locking clamps use a flathead screwdriver to assist b Remove the fan c Clean the cooling air duct and the heat sink with compressed air See separate instructions in section 2 1 1 d Check that the fans blowing direction is inside the unit and install t...

Page 18: ...l panel b Open mounting screw with a screwdriver c Push the front cover slightly upwards and lift it off Remove control unit a Remove mounting screws with a screwdriver b Release mounting clamps and lift CCU 11 CCU 23 and the rigid connector off Replace internal fan a Remove internal fan sledge and cable from plastic housing b Assembly new internal fan sledge combination i Place internal fan to sl...

Page 19: ... to change without notice 2 2 11 New Frame R3 Main cooling fan Types ACX580 01 046A 2 ACX580 01 047A 2 ACX580 01 059A 2 ACX580 01 060A 2 ACX580 01 027A 4 ACX580 01 033A 4 ACX580 01 034A 4 ACX580 01 039A 4 ACX580 01 044A 4 ACX580 01 046A 4 ACX580 01 022A 6 ACX580 01 027A 6 ACX580 01 032A 6 The main cooling fan is located on the top of the drive Replace the fan as follows 1 Release the locking clamp...

Page 20: ...rved Specifications subject to change without notice 2 Remove the fan by opening the unit and pushing rightwards at the base 3 Clean the cooling air duct and the heat sink with compressed air See separate instructions in section 2 1 1 4 Check that the fans blowing direction is outside the unit and install the new fan unit simply by pushing it to its place Ensure the fan operation when the drive is...

Page 21: ...A 2 ACX580 01 059A 2 ACX580 01 060A 2 ACX580 01 027A 4 ACX580 01 033A 4 ACX580 01 034A 4 ACX580 01 039A 4 ACX580 01 044A 4 ACX580 01 046A 4 ACX580 01 022A 6 ACX580 01 027A 6 ACX580 01 032A 6 1 Remove front cover a Remove control panel b Open mounting screws with a screwdriver c Push the front cover slightly upwards and lift it off 2 Replace the internal fan a Remove internal fan plastic housing b ...

Page 22: ...A 4 ACX580 01 045A 4 The main cooling fan is located at the bottom of the drive Replace the fan as follows a Release the locking clamp use a flathead screwdriver to assist b Remove the fan by opening the unit 1 and pushing leftwards at the base 2 c Clean the cooling air duct and the heat sink with compressed air See separate instructions in section 2 1 1 d Check that the fans blowing direction is ...

Page 23: ...tice 2 2 14 Old Frame R3 IP55 Internal cooling fan Types ACX580 01 032A 4 ACX580 01 038A 4 ACX580 01 045A 4 Remove front cover a Remove control panel b Open mounting screws with a screwdriver c Push the front cover slightly upwards and lift it off Replace internal fan a Remove internal fan plastic housing b Remove fan connector from CCU 11 CCU 23 c Replace internal fan see that the blowing directi...

Page 24: ...2 ACX580 01 052A 4 ACX580 01 065A 4 ACX580 01 077A 4 The main cooling fan is located at the bottom of the drive Replace the fan as follows a Release the locking clamp use a flathead screwdriver to assist b Remove the fan by opening the unit 1 and pushing leftwards at the base 2 c Clean the cooling air duct and the heat sink with compressed air See separate instructions in section 2 1 1 d Check tha...

Page 25: ... 2 2 16 Frame R4 IP55 Internal cooling fan Types ACX580 01 062A 4 ACX580 01 073A 4 ACX580 01 075A 2 ACX580 01 076A 2 ACX580 01 052A 4 ACX580 01 065A 4 ACX580 01 077A 4 Remove front cover a Remove control panel b Open six mounting screw with a screwdriver c Push the front cover slightly upwards and lift it off Remove internal fan a Remove fan connector and detach fan cable from clamps b Pull fan ou...

Page 26: ...ain cooling fan is located at the bottom of the drive Replace the fan as follows a Remove the drive cover and gland box cover Remove gland box to reveal main fan b Pull the main fan out the drive by pressing the holding clamps Release the fan wire from the drive and remove the fan c Clean the cooling air duct and the heat sink with compressed air See separate instructions in section 2 1 1 d Check ...

Page 27: ...ing fan Types ACX580 01 106A 4 ACX580 01 088A 2 ACX580 01 089A 2 ACX580 01 114A 2 ACX580 01 115A 2 ACX580 01 078A 4 ACX580 01 096A 4 ACX580 01 041A 6 ACX580 01 052A 6 ACX580 01 062A 6 ACX580 01 077A 6 Remove front cover a Remove control panel b Open mounting screws with a screwdriver c Push the front cover slightly upwards and lift it off Remove internal fan a Remove fan connector and detach fan c...

Page 28: ...wire from the drive and remove the fan g Clean the cooling air duct and the heat sink with compressed air See separate instructions in section 2 1 1 h Check that the fans blowing direction is outwards from the unit Attach the fan wire to the drive and install the new fan Ensure the fan operation when the drive is powered up 2 2 20 Old Frame R5 Internal cooling fan Types ACX580 01 061A 4 ACX580 01 ...

Page 29: ... the machinery can be performed without switching off the power supply of the drive WARNING The Safe torque off function does not disconnect the voltage of the main and auxiliary circuits from the drive Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive from the main supply WARNING With permanent magnet motors only In case of ...

Page 30: ...ctions against the wiring diagram Close the disconnector and switch the power on Test the operation of the STO function when the motor is stopped Give a stop command for the drive if running and wait until the motor shaft is at a standstill Ensure that the drive operates as follows Open the STO circuit The drive generates an indication if one is defined for the stopped state in parameter 31 22 STO...

Page 31: ...ontrol panel cable Pay attention to the connectors and jumpers when installing CCON to its assembly mechanics 2 3 4 Removing CCON 12 from its assembly mechanics In case there is a need to remove the control board from its assembly mechanics operate as follows a Release the locking clamps and lift the board from its assembly plate Pay attention to terminals and jumpers b Replace CCON Pay attention ...

Page 32: ... 01 04A1 4 ACX580 01 04A8 4 ACX580 01 05A7 4 ACX580 01 06A0 4 ACX580 01 07A3 4 ACX580 01 07A6 4 ACX580 01 09A9 4 ACX580 01 012A 4 ACX580 01 12A7 4 Remove front cover a Remove control panel b Open one mounting screw with a crosshead screwdriver c Lift the front cover from the bottom and simultaneously push it upwards Replace CCU 11 or CCU 23 unit a Remove two fixing screws M3x10 b Loosen the lockin...

Page 33: ...580 01 06A1 6 ACX580 01 09A0 6 ACX580 01 011A 6 ACX580 01 017A 6 Remove front cover a Remove control panel b Open one mounting screw with a crosshead screwdriver c Push the front cover slightly upwards and lift it off Replace CCU 11 or CCU 23 unit a Remove two fixing screws M3x10 b Loosen the locking clamps and pull the CCU unit off Use a flathead screwdriver to assist Pay attention to the rigid c...

Page 34: ...580 01 046A 4 ACX580 01 022A 6 ACX580 01 027A 6 ACX580 01 032A 6 Remove front cover a Remove control panel b Open one mounting screw with a crosshead screwdriver c Push the front cover slightly upwards and lift it off Replace CCU 11 or CCU 23 unit a Remove two fixing screws M3x10 b Loosen the locking clamps and pull the CCU unit off Use a flathead screwdriver to assist Pay attention to the rigid c...

Page 35: ...ACX580 01 062A 6 ACX580 01 077A 6 Remove front cover a Remove control panel b Open one mounting screw with a crosshead screwdriver c Push the front cover slightly upwards and lift it off Replace CCU 11 or CCU 23 unit a Remove two fixing screws M3x10 b Loosen the locking clamps and pull the CCU unit off Use a flathead screwdriver to assist Pay attention to the rigid connector in the upper right cor...

Page 36: ... 052A 6 B056 ACX580 01 062A 6 B056 ACX580 01 077A 6 B056 Remove front cover a Remove control panel b Open six mounting screws with a screwdriver c Push the front cover slightly upwards and lift it off Replace CCU 11 or CCU 23 unit a Remove fan connector b Remove two fixing screws M3x10 c Loosen the locking clamps and pull the CCU unit off Use a flathead screwdriver to assist Pay attention to the r...

Page 37: ... to change without notice 2 3 11 Frame R5v1 CCU 12 replacement Types ACX580 01 061A 4 ACX580 01 072A 4 ACX580 01 087A 4 Remove front cover a Remove control panel b Open two mounting screws with a torxhead screwdriver c Remove the front cover Replace CCU 12 unit a Disconnect wires from CCU b Remove fixing screws 2pcs of M4x8 and 4pcs of 4x12 PT Install components in reverse order Use tightening tor...

Page 38: ...062A 6 ACX580 01 077A 6 Remove front cover a Remove control panel b Open one mounting screw with a crosshead screwdriver c Push the front cover slightly upwards and lift it off Replace CCU 11 or CCU 23 unit a Remove two fixing screws M3x10 b Loosen the locking clamps and pull the CCU unit off Use a flathead screwdriver to assist Pay attention to the rigid connector in the upper right corner under ...

Page 39: ...re that there is no voltage connected to input terminals In case a permanent magnet motor is used the motor axel must not rotate as it would feed voltage to drive side STEP 1 Input bridge diode measurement Performance Use a multimeter to make sure that the measurements for the input bridge diodes are OK Pass criteria By using the diode measurement setting for the multimeter you should get followin...

Page 40: ... Freewheeling diode measurement Performance Use a multimeter to make sure that the measurements for the output freewheeling diodes are OK Pass criteria By using the diode measurement setting for the multimeter you should get following values probe probe R1 R5 display U DC 0 4 Vdc V DC 0 4 Vdc W DC 0 4 Vdc DC U OL DC V OL DC W OL probe probe R1 R5 display U DC OL V DC OL W DC OL DC U 0 4 Vdc DC V 0...

Page 41: ...rol unit ACX580 CCU control unit contains three option slots In the table below there is described which interface options can be used in which slot Option modules Install to Fieldbus adapters FENA FPBA Slot 1 I O extensions CMOD Slot 2 Embedded fieldbus CEIA Slot 3 Install the optional modules as follows 1 Insert the module carefully into its position on the control board 2 Fasten the fastening s...